Fiber optic manufacturing in space

Abstract

Aspects of the embodiments are directed to systems and methods for forming an optical fiber in a low gravity environment, and an optical fiber formed in a low gravity environment. The system can include a preform holder configured to secure a preform; a heating element secured to a heating element stage and residing adjacent the preform holder; a heating element stage motor configured to move the heating element stage; a tension sensor; a spool; a spool tension motor coupled to the spool and configured to rotate the spool; and a control system communicably coupled to the heating element stage motor and the spool tension motor and configured to control the movement of the heating element stage based on a rotational speed of the spool. The optical fiber can include a fluoride composition, such ZrF4-BaF2-LaF3-AlF3-NaF (ZBLAN), and can be characterized by an insertion loss in a range from 13 dB/1000 km to 120 dB/1000 km.

What is claimed is: 
     
       1. A system for forming an optical fiber in a low gravity environment, the system comprising:
 a preform holder configured to secure a preform; 
 a heating element secured to a heating element stage and residing adjacent the preform holder; 
 a heating element stage motor configured to move the heating element stage; 
 a tension sensor; 
 a spool; 
 a spool tension motor coupled to the spool and configured to rotate the spool; and 
 a control system communicably coupled to the heating element stage motor and the spool tension motor and configured to control the movement of the heating element stage based on a rotational speed of the spool. 
 
     
     
       2. The system of  claim 1 , further comprising a preform secured in the preform holder, wherein the tension sensor is coupled to the preform holder and configured to monitor a tension on the preform. 
     
     
       3. The system of  claim 2 , wherein the heating element surrounds the preform. 
     
     
       4. The system of  claim 1 , further comprising a spool translation motor configured to translate the spool along a long axis of the spool. 
     
     
       5. The system of  claim 1 , wherein the control system is configured to control a temperature of the heating element. 
     
     
       6. The system of  claim 1 , wherein the control system is configured to control the spool tension motor to control a tension applied to a preform. 
     
     
       7. The system of  claim 1 , wherein the tension sensor comprises a load cell. 
     
     
       8. The system of  claim 1 , further comprising a surface coating retention element surrounded by the heating element, the surface coating retention element configured to apply a coating onto a fiber. 
     
     
       9. A method for forming an optical fiber in a low gravity environment, the method comprising:
 providing a preform in a preform drawing apparatus in the low gravity environment; 
 engaging the preform with a spool under an initial temperature; 
 turning the spool until a desired tension on the preform has been reached; 
 increasing the temperature of the preform until a desired spool speed is reached; and 
 locking the temperature of the preform. 
 
     
     
       10. The method of  claim 9 , further comprising:
 heating a coating material with the preform; and 
 coating the optical fiber with the coating material during formation of the optical fiber. 
 
     
     
       11. The method of  claim 9 , wherein increasing the temperature of the preform comprises heating the preform in an oven that surrounds the preform. 
     
     
       12. The method of  claim 11 , further comprising adjusting a position of the oven as the preform changes, wherein adjusting the position of the oven is based, at least in part, on the spool speed. 
     
     
       13. The method of  claim 9 , further comprising heating the preform to an initial temperature prior to engaging the preform with the spool. 
     
     
       14. The method of  claim 9 , wherein the desired spool speed is based, at least in part, on a desired diameter of the optical fiber. 
     
     
       15. The method of  claim 9 , wherein turning the spool comprises applying a torque to the spool by a computer-controlled motor. 
     
     
       16. The method of  claim 9 , wherein providing the preform in a preform drawing apparatus in the low gravity environment comprises providing the preform in a platform or vehicle orbiting the Earth. 
     
     
       17. An optical fiber drawn in a low gravity environment in accordance with the method of any of  claims 9 - 16 . 
     
     
       18. The optical fiber of  claim 17 , wherein the optical fiber comprises fluoride. 
     
     
       19. The optical fiber of  claim 18 , wherein the optical fiber comprises ZrF4-BaF2-LaF3-AlF3-NaF (ZBLAN). 
     
     
       20. The optical fiber of  claim 17 , wherein the optical fiber comprises an insertion loss in a range from 13 dB per 1000 km to 120 dB per 1000 km.